1. No category

Structural Design and
Analysis of Composite
Materials using SAMCEF
for Composites
SL/04/SAM/MKG_ppt/32an_b
30/03/06, Page 1
SAMCEF for Composites
9 Composite Materials Structural Analysis : Specific Issues
9 SAMCEF general capabilities for Composite Materials
Analysis
9 SAMCEF Field integrated pre- and post-processor
• Basic Features for Composite Materials Modelling and
Analysis
• Applications
9 Conclusions – Benefits of Using SAMCEF for Composites
30/03/06, Page 2
Composite Materials Structural Analysis
Specific Issues (1/4)
9Anisotropic and heterogeneous nature.
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Need for sophisticated tools at macro (i.e. laminate), meso (i.e. ply)
and micro (i.e. phases (fibers, matrix,..)) levels.
Important volume of operations at pre- and post-processing stages.
9Low secondary strength.
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Transverse loads need to be accurately estimated.
30/03/06, Page 3
Composite Materials Structural Analysis
Specific Issues (2/4)
9No plastic adaptation.
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Long continuous fibers systems.
Need for accurate prediction of critical
3D inter-laminar stress states.
“Do not forgive design errors !”.
9Complex coupled failure modes.
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Fibers break, transverse matrix cracking, delamination, …
Need for sophisticated degradation models.
30/03/06, Page 4
Composite Materials Structural Analysis
Specific Issues (3/4)
9Sensitivity to transverse shear effects.
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Critical matrix dominated behaviors.
Thick sandwich constructions (e.g. shipbuilding).
Possible need for higher order shell or complex 3D solid elements.
9Huge amount of data and results processing for practical
size structures.
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Need for appropriate pre- and postprocessing procedures including
extensive visualization tools.
Courtesy SONACA
30/03/06, Page 5
Composite Materials Structural Analysis
Specific Issues (4/4)
9Need for advanced SW tools in other topics of vital
importance for the design process.
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Durability (fatigue, ageing, impact, ..).
Joining (bolted, riveted, adhesive joints).
Characterization.
Process simulation.
Optimization (layups, plies orientations, thicknesses, ..).
….
9Analysis at earlier stage than in metals.
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Material architecture is selected for manufacturing feasibility and
structural performance.
30/03/06, Page 6
SAMCEF general capabilities (1/3)
‰ Provides extended set of advanced capabilities for
the modeling and analysis of composite materials
structures
9 Comprehensive library of dedicated multi-layered
elements
Sandwich
constructions
30/03/06, Page 7
SAMCEF general capabilities (2/3)
9 Large variety of analyses
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Linear thermo-mechanical static analysis;
Modal analysis;
Transient response;
Linear and incremental stability;
Non-linear static, dynamic and kinematic analyses;
Non-linear thermal analysis;
Fast Dynamics (Europlexus explicit solver)
Rotor dynamics;
Optimization (BOSS Quattro : topology, shape and size).
30/03/06, Page 8
SAMCEF general capabilities (3/3)
9 Dedicated pre- and post-processing procedures
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Material properties;
Plies creation (matl, angle,thickness);
Laminates definition (lay-ups);
Laminates assignment to FE mesh;
Ply by ply results recovery (stress/strains/failure
criteria);
Critical ply selection (large range of failure
theories);
Damage distribution.
30/03/06, Page 9
SAMCEF Field integrated pre- and postprocessor
9Integrated user friendly environment for CAE
applications
9Modelling, Analysis and Results processing
9Linear and Non-linear Thermo-mechanical
Structural Analyses, MBS, Multi-physics, Rotor
dynamics …
9 Contextual Menus
9 Data Library
9 “Parts” concept allowing concurrent model
development
30/03/06, Page 10
SAMCEF Field integrated pre- and postprocessor – Basic features
SAMCEF general capabilities
for Composite Materials
Analysis
Supports a subset of
general tool features
Access to non supported
features via the “epilogue” in
SAMCEF native language
SAMCEF Field Open
Interactive Environment for
Composite Materials Analysis
30/03/06, Page 11
SAMCEF Field integrated pre- and postprocessor – Basic features
Material Library
9Material data import from
data library
9Material data definition
(possibly temperature
dependent) and storage in
data library
30/03/06, Page 12
SAMCEF Field integrated pre- and postprocessor – Basic features
Elements Types Selection (Behaviour) (1/2)
9Composite Shell
• Transverse shear deformable thick
shell element
• Based on Classical Lamination Theory
• Can be used for sandwich constructions
modelling within scope of CLT
2
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30/03/06, Page 13
SAMCEF Field integrated pre- and postprocessor – Basic features
Elements Types Selection (Behaviour) (2/2)
9Composite Volume (Shell)
• Recommended when CLT is no longer
valid (e.g. severe cross section warping
of thick sandwich constructions)
• Possible superimposition of several
multilayered solids if needed.
• “Composite Volumic Shell” formulation :
σzz is uncoupled from in plane stress components Æ shell-like
behaviour.
30/03/06, Page 14
SAMCEF Field integrated pre- and postprocessor – Basic features
Plies and laminates creation
9Individual Ply
• Matl, Thickness, Angle
9Laminate
• Creation and ordering of the plies
making up the lay-up.
• Use of the Composite Viewer
30/03/06, Page 15
SAMCEF Field integrated pre- and postprocessor – Basic features
The Composite Viewer (1/3)
Tools set for plies
manipulation
Lay-up sequential
definition
Display area
9 Easy, intuitive and efficient lay-ups definition
30/03/06, Page 16
SAMCEF Field integrated pre- and postprocessor – Basic features
The Composite Viewer (2/3)
9 Tools set
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Add, insert, delete plies;
Copy, paste;
Move selected ply up and down in the list;
Create symmetric or anti-symmetric laminate;
Reverse plies orientations;
9 Definition list
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Layer sequential number, name,
material, thickness and orientation.
30/03/06, Page 17
SAMCEF Field integrated pre- and postprocessor – Basic features
The Composite Viewer (3/3)
9 Display Area
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Graphical representation of the
laminate as it is being created;
Shows layers orientation
and relative thickness.
9 Equivalent stiffness properties
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Polar plots of equivalent membrane,
shear, bending and torsion moduli
30/03/06, Page 18
SAMCEF Field integrated pre- and postprocessor – Basic features
Laminates assignment to CAD geometry (1/5)
9 Draping is simulated with reference to laminate position
in structural (OXY, OYZ, OXZ) or user’s defined plane
9 Predicts how laminates conform to complex surfaces and
generates automatically fibres orientations distribution
Laminate local zero deg.
direction in reference plane
30/03/06, Page 19
SAMCEF Field integrated pre- and postprocessor – Basic features
Laminates assignment to CAD geometry (2/5)
9 For composite shells, options are provided to define
offsets from the mould surface
30/03/06, Page 20
SAMCEF Field integrated pre- and postprocessor – Basic features
Laminates assignment to CAD geometry (3/5)
Draping simulation of two laminates over a
portion of a cone
30/03/06, Page 21
SAMCEF Field integrated pre- and postprocessor – Basic features
Laminates assignment to CAD geometry (4/5)
9 Visualisation of expanded lay-up and particular ply on a
selected face
30/03/06, Page 22
SAMCEF Field integrated pre- and postprocessor – Basic features
Laminates assignment to CAD geometry (5/5)
9 Volumic elements : laminate is assigned to a face of a
solid
9 The F.E. mesh is generated by extrusion
9 Restriction in V5.2 : only one laminate per elements layer !
Æ will be lifted in release 6.0
30/03/06, Page 23
SAMCEF Field integrated pre- and postprocessor – Basic features
Analysis results archiving (Solver Module)
9 Selection from pre-defined
list of SAMCEF results
codes
9 Additional results codes
can be selected
30/03/06, Page 24
SAMCEF Field integrated pre- and postprocessor – Basic features
Specific post-processing (1/2)
9 SAMCEF for Composites capabilities facilitate in-depth
analysis of composite constructions behaviours.
9 Ply by ply stress/strain/failure criteria results recovery
(nodal or average values)
9 For shell elements , results are provided on lower and
upper faces as well as mid-surface of each ply
9 Transverse shear stresses are determined from local
equilibrium equations per layer (Shell elements)
• Piecewise parabolic distribution
• Stress continuity at interfaces
• Upper and lower faces free of stress
τxz = τyz = 0
30/03/06, Page 25
SAMCEF Field integrated pre- and postprocessor – Basic features
Specific post-processing (2/2)
9 Failure theories
• Max stress, Max strain
• Tsai-Hill
• Tsai-Wu
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Hoffman
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Hashin : multicriteria allowing to identify matrix and fiber failure
modes
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Rice and Tracey
9 Fringe plots of critical values (and corresponding ply
number) through laminate thickness allowing immediate
access to critical areas and assessment of structure
integrity
30/03/06, Page 26
SAMCEF Field integrated pre- and postprocessor – Application 1
Loading and boundary conditions
Uniform pressure
Simple support
30/03/06, Page 27
SAMCEF Field integrated pre- and postprocessor – Application 1
Finite Element mesh generation
9 Mesh generation using mapping method
30/03/06, Page 28
SAMCEF Field integrated pre- and postprocessor – Application 1
Deformed geometry
30/03/06, Page 29
SAMCEF Field integrated pre- and postprocessor – Application 1
Fringe plot of Tsai-Wu failure criterion - Critical Value
30/03/06, Page 30
SAMCEF Field integrated pre- and postprocessor – Application 1
Locating most critical area
30/03/06, Page 31
SAMCEF Field integrated pre- and postprocessor – Application 1
Critical ply number
30/03/06, Page 32
SAMCEF Field integrated pre- and postprocessor – Application 1
Orientation of ply # 1
30/03/06, Page 33
SAMCEF Field integrated pre- and postprocessor – Application 1
Tsai-Wu failure criterion contours – Ply # 1
9 Element selection (cursor)
9 Ply selection
(composite viewer)
30/03/06, Page 34
SAMCEF Field integrated pre- and postprocessor – Application 1
Transverse stress component contours (σ2) – Ply # 1
30/03/06, Page 35
SAMCEF Field integrated pre- and postprocessor – Application 2
Composite Stamping Tool – Courtesy EADS Suresnes
30/03/06, Page 36
SAMCEF Field integrated pre- and postprocessor – Application 2
Loading (uniform temperature) and boundary conditions
30/03/06, Page 37
SAMCEF Field integrated pre- and postprocessor – Application 2
View of the F.E. mesh
30/03/06, Page 38
SAMCEF Field integrated pre- and postprocessor – Application 2
Deformed geometry
30/03/06, Page 39
SAMCEF Field integrated pre- and postprocessor – Application 2
Fringe plot of Tsai-Wu failure criterion – Critical Values
30/03/06, Page 40
SAMCEF Field integrated pre- and postprocessor – Application 2
Critical Ply number
30/03/06, Page 41
SAMCEF Field integrated pre- and postprocessor – Application 2
Tsai-Wu failure criterion contours – Ply # 5
9 Element selection (cursor)
9 Ply selection
(composite viewer)
30/03/06, Page 42
SAMCEF Field integrated pre- and postprocessor – Application 2
Transverse stress component contours (σ2) – Ply # 5
30/03/06, Page 43
SAMCEF Field integrated pre- and postprocessor – Application 3
F1 Composite Air Exhaust – Courtesy DUQUEINE
Composites
30/03/06, Page 44
SAMCEF Field integrated pre- and postprocessor – Application 3
Loading and boundary conditions
30/03/06, Page 45
SAMCEF Field integrated pre- and postprocessor – Application 3
View of the F.E. mesh
30/03/06, Page 46
SAMCEF Field integrated pre- and postprocessor – Application 3
Deformed geometry
30/03/06, Page 47
SAMCEF Field integrated pre- and postprocessor – Application 3
Fringe plot of Hashin failure criterion – Critical Values
30/03/06, Page 48
SAMCEF Field integrated pre- and postprocessor – Application 3
Critical Ply number
30/03/06, Page 49
SAMCEF Field integrated pre- and postprocessor – Application 3
Hashin failure criterion contours – Ply # 1
9 Element selection (cursor)
9 Ply selection
(composite viewer)
30/03/06, Page 50
SAMCEF Field integrated pre- and postprocessor – Application 3
Transverse stress component contours (σ2) – Ply # 1
30/03/06, Page 51
Conclusions – Benefits of Using SAMCEF
for Composites
9 Operates entirely from within standalone, fully integrated
contextual environment supporting a concurrent
engineering methodology.
9 Modelling, Analysis and Results processing
9 Easy-to-use and user-friendly composite viewer for
plies/laminates creation and manipulation
9 In-depth analysis of laminates thermo-mechanical behavior.
9 Immediate access to critical areas
30/03/06, Page 52